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The 3D virtual full-loop CFD simulation method with two-fluid model (TFM) was developed to model an industrial two-stage FCC reaction–regeneration system. The virtual connections (mass, species, and energy) between riser reactors, disengager, stripper, and regenerator were realized by defining user-defined functions (UDFs) for boundary conditions according to the reality. Five correction factors were used to correct the reaction rates in the 14-lump FCC reaction kinetics, and two correction factors were used to correct the FCC reaction heat in the first and second riser reactors. As a result, the whole FCC reaction–regeneration system was successfully modeled in one single CFD case. A thorough and comprehensive view of the performance of reaction–regeneration system was obtained by the 3D virtual full-loop CFD simulation, which is helpful for the operating and optimization of FCC unit. The major predicted results were in a good agreement with the industrial data. The effects of operating conditions were also investigated by changing regenerated temperature, catalyst to oil (CTO) ratio, and process capacity.

3D virtual full-loop CFD simulation of industrial two-stage FCC reaction–regeneration system